Rail-Based Solar Panel Mounting System

Abstract

A rail-based solar panel mounting system including at least one mounting bracket coupled to a mounting surface and at least one elongated rail having an open channel configuration, wherein the at least one elongated rail is coupled to the at least one mounting bracket. The mounting system also includes at least one mid-clamp assembly couplable to the at least one elongated rail, wherein the at least one mid-clamp assembly is configured to retain at least one solar panel relative to the at least one elongated rail.

What is claimed is: 
     
         1 . A rail attachment bracket for securing to a roof attachment with a fastener member, the fastener member having a drive head and a threaded shank, and for securing to a rail, the rail having a channel, the rail attachment bracket comprising:
 a first clamp portion, the first clamp portion having an elongated upper extension, an upper base portion, and a lower base portion, the elongated upper extension configured to interface with the channel, the upper base portion extending laterally, the first clamp portion being configured to receive the fastener;   a coupling member, the coupling member having a support portion and at least two resilient arms; and   a second clamp portion, the second clamp portion having an elongated upper extension and an upper base portion which extends laterally, the second clamp portion being configured to receive the fastener, wherein the coupling member is at least partially between the first clamp portion and the second clamp portion; and   wherein in a first state an abutment surface of the second clamp portion and the lower base portion are spaced apart and in a second state the abutment surface of the second clamp portion and the lower base portion are in contact.   
     
     
         2 . The rail attachment bracket of  claim 1 , wherein the first clamp portion comprises a groove, the groove configured to accommodate the coupling member. 
     
     
         3 . The rail attachment bracket of  claim 2 , wherein the support portion of the coupling member fits within the groove and the at least two resilient arms extend laterally from the support portion. 
     
     
         4 . The rail attachment bracket of  claim 2 , wherein the second clamp portion includes a slot which receives a T-shaped head portion at the ends of the resilient arms. 
     
     
         5 . The rail attachment bracket of  claim 1 , wherein the coupling member includes a ring, the ring configured to receive the threaded shank. 
     
     
         6 . The rail attachment bracket of  claim 1 , wherein a lower base portion of the second clamp portion contacts the lower base portion of the first clamp portion when the fastener is in the first state and the second state. 
     
     
         7 . The rail attachment bracket of  claim 1 , wherein the elongated upper extension of the second clamp portion is configured to interface with the channel. 
     
     
         8 . A rail attachment bracket for securing a roof attachment with a fastener member, the fastener member having a drive head and a threaded shank, and for securing to a rail, the rail having a channel, the rail attachment bracket comprising:
 a first clamp portion, the first clamp portion having an elongated upper extension, an upper base portion, a lower base portion, and an annular recess, the elongated upper extension contacts the channel;   a coupling member, the coupling member having a support portion, a ring, and at least two resilient arms; and   a second clamp portion, the second clamp portion having an elongated upper extension, an upper base portion, and a threaded hole, the upper base portion extending laterally;   wherein the threaded shank of the fastener member extends through the annular recess of the first clamp portion, the ring of the support portion, and the threaded hole of the second clamp portion;   wherein the first clamp portion comprises a groove, the groove being lower than the upper base portion and higher the lower base portion and configured to receive the coupling member, the upper base portion extending laterally over the coupling member in an assembled state.   
     
     
         9 . The rail attachment bracket of  claim 8 , wherein the shank of the fastener extends through the groove of the first clamp portion. 
     
     
         10 . The rail attachment bracket of  claim 8 , wherein support portion of the coupling member fits within the groove and the at least two resilient arms extend laterally from the support portion. 
     
     
         11 . The rail attachment bracket of  claim 8 , wherein one of the first clamp portion or second clamp portions includes a slot which receives at least one enlarged end of the coupling member. 
     
     
         12 . The rail attachment bracket of  claim 8 , wherein the ring of the coupling member is configured to receive the threaded shank. 
     
     
         13 . The rail attachment bracket of  claim 8 , wherein the second clamp portion includes an abutment surface configured to receive the lower base portion of the first clamp portion. 
     
     
         14 . The rail attachment bracket of  claim 8 , wherein the elongated upper extension of the second clamp portion is configured to interface with the channel. 
     
     
         15 . A rail attachment bracket for securing to a roof attachment with a fastener member, the fastener member having a drive head and a threaded shank, and for securing to a rail, the rail having a channel, the rail attachment bracket comprising:
 a first clamp portion, the first clamp portion having an elongated upper extension, an upper base portion, and a lower base portion, the elongated upper extension configured to interface with the channel, the upper base portion extending laterally, the first clamp portion being configured to receive the fastener;   a coupling member, the coupling member having a support portion, a T-shaped head portion, and at least two resilient arms; and   a second clamp portion, the second clamp portion having an elongated upper extension and an upper base portion which extends laterally, the second clamp portion being configured to receive the fastener, wherein the coupling member is at least partially between the first clamp portion and the second clamp portion; and   wherein the upper extension of the first clamp portion is configured to provide a hook-like interface connection with the channel of the rail.   
     
     
         16 . The rail attachment bracket of  claim 15 , wherein the upper extension of the first clamp and the upper extension of the second clamp are equal in height. 
     
     
         17 . The rail attachment bracket of  claim 15 , wherein the upper base portion of the first clamp portion extends further laterally than the upper base portion of the second clamp portion. 
     
     
         18 . The rail attachment bracket of  claim 17 , wherein the first clamp portion has a central portion, the central portion of the first clamp portion defining a through hole configured for receiving the fastener member, and wherein the upper base portion of the first clamp portion extends laterally further than the central portion of the first clamp portion. 
     
     
         19 . The rail attachment bracket of  claim 15 , wherein in a first state an abutment surface of the second clamp portion and the lower base portion are spaced apart and in a second state the abutment surface of the second clamp portion and the lower base portion are in contact. 
     
     
         20 . The rail attachment bracket of  claim 15 , wherein the first clamp portion comprises a groove, the groove being lower than the upper base portion and higher the lower base portion and configured to receive the coupling member, the upper base portion extending laterally over the coupling member in an assembled state.